Modular pallet construction

ABSTRACT

A modular pallet includes a deck, a plurality of beam members defining a frame for supporting the deck and each having a surface mechanically coupled with the deck, and one or more cross members mechanically coupled with each of the beam members such that the beam members have a substantially fixed spatially relationship relative to each other. The deck, beam members, and cross members can be easily assembled and disassembled.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/821,995, filed Aug. 10, 2006 and entitled “Modular Pallet Construction,” the disclosure of which is expressly incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

This invention relates generally to pallets and, more particularly, to pallets having a modular construction for ease of assembly and disassembly.

BACKGROUND

Pallets are well known structures for supporting different types of loads for transportation and shipment. The load may be secured to the pallet by tensioned high strength steel or plastic strapping passing over the load and down around the pallet, or by stretch-wrapped plastic film. Pallets are used to ship loads consisting of freight, boxed, cartoned or otherwise packaged goods, or other materials. The gradual advent of containers for the transport of most goods has spurred the use of pallets because the containers always offer clean, level surfaces required to make pallet transport economical.

Generally, conventional pallets include multiple runners or stringers and a deck consisting of a corrugated cardboard sheet, a plywood sheet, or a number of wood slats that span the underlying stringers. The vast majority of conventional pallets currently in use have a wood slat deck. Adhesive, nails, screws, staples, or the like secure the deck to the stringers, which raises or elevates the deck above floor or ground level. The deck provides a support surface for the load carried by the pallet. This permits a forklift truck, commonly called a forklift, to place fork tines under the load in the space between the deck and the floor or ground and lift the pallet and its load for transfer to a different location. The ability to lift the pallets permits stacking that may minimize the floor space occupied by loaded pallets.

Conventional pallets have a rigid construction and are not designed to be readily disassembled. For instance, pallets assembled with permanent fasteners, such as nails and screws, cannot be easily disassembled and then reassembled. Consequently, during these periods of non-use after their loads are removed, conventional pallets remain in an assembled state and are stored. Typically, idle pallets, which are susceptible to weather damage, are stacked in sheltered floor space within the facility (e.g., plant, warehouse, retail store, etc.). Unfortunately, the high-volume stored pallets needlessly occupy valuable facility floor space, even when the pallets are stored in a stacked configuration. Likewise, when transporting pallets, either for initial use or reuse, relatively few pallets may be transported in a given floor space. As a result of the inefficient use of space, storing and transporting pallets during periods of non-use can be burdensome.

Therefore, a need exists for a pallet construction that reduces the storage problems associated with conventional pallets.

SUMMARY

Embodiments of the invention is generally directed to a modular pallet with recyclable components that reduces or eliminates the storage problems associated with conventional pallets. In one specific embodiment, the pallet includes a deck and a plurality of beam members defining a frame for supporting the deck. Additionally, at least one cross member is mechanically coupled with each of the beam members such that the beam members have a substantially fixed spatial relationship relative to each other. Each cross member may be removable from the beam members, after the deck is removed, for disassembling the pallet.

A method of reusing a pallet according to one embodiment of the invention generally comprises removing the deck from the beam members, disassembling at least one cross member from the beam members, and transporting the disassembled beam members and the at least one cross member from a first location to a second location. The at least one cross member and the beam members may then be reassembled at the second location, and a deck may be coupled to the reassembled beam members to allow reuse of the pallet.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.

FIG. 1 is a partially disassembled perspective view of the components of a pallet according to one embodiment of the invention;

FIG. 2 is a side elevational view, partially broken away, illustrating a portion of a cross member and a portion of a stringer of the pallet of FIG. 1 in further detail;

FIG. 3 is a side elevational view of a cross member used to connect stringers of the pallet of FIG. 1;

FIG. 4 is an enlarged perspective view of an end portion of one of the stringers of the pallet of FIG. 1;

FIG. 5 is a disassembled perspective view of a stringer and a deck of the pallet of FIG. 1;

FIG. 6 is a disassembled perspective view of a stringer and a deck of a pallet according to an alternative embodiment;

FIG. 7 is a diagrammatic cross-sectional view of an adhesive stud used to couple a deck and a stringer of a pallet according to a further embodiment of the invention;

FIG. 8 is a disassembled perspective view of a stringer and a deck of a pallet according to another embodiment of the invention;

FIG. 9 is a disassembled perspective view of the components of a pallet according to yet another embodiment of the invention;

FIG. 10 is a side elevational view of a cross member used to connect stringers of the pallet of FIG. 9;

FIG. 11 is an enlarged perspective view of an end portion of a stringer of the pallet of FIG. 9; and

FIG. 12 is a disassembled perspective view similar to FIG. 11 showing a cross member being removably coupled to the end portion of the stringer.

DETAILED DESCRIPTION

FIG. 1 shows the components of a pallet 10 according to one embodiment of the invention. The pallet 10 includes a deck 12 defining an upper surface 14 configured to support a load (not shown) for transport and a lower surface 16 opposite the upper surface 14. Multiple beam members having the representative form of stringers 18 are mechanically coupled to the lower surface 16 when the pallet 10 is assembled, as will be described in greater detail below. The stringers 18 are located between the deck 12 and the ground or floor. Additionally, although the pallet 10 is shown as including three stringers 18, it will be appreciated that a smaller or larger number of stringers 18 may be used to construct the pallet 10.

The stringers 18 are arranged to define a frame for supporting the deck 12 above a ground surface and may include one or more cutouts 20 facing the ground surface for accommodating forklift tines (not shown). For example, the stringers 18 may be positioned so that the cutouts 20 on each stringer 18 are aligned with corresponding cutouts 20 on the other stringers 18. When the pallet 10 is assembled and lifted by a forklift or other fork-based warehouse handling system (not shown), the forklift tines project through the aligned cutouts 20 so that all of the stringers 18 may be supported above the ground surface. The stringers 18 may also be aligned substantially parallel to each other so that the forklift tines may alternatively be inserted into the space between adjacent stringers 18. In such a situation, the forklift tines contact the lower surface 16 of the deck 12 instead of the cutouts 20 when lifting the pallet 10.

Each of the stringers 18 includes a top surface 26 confronting the lower surface 16 of the deck 12 and a bottom surface 28 opposite the corresponding top surface 26. The pallet 10 may further include a lower deck (not shown) coupled to the bottom surface 28 of each stringer 18. This lower deck may useful for stacking pallets 10 that carry loads presenting an uneven upper surface to overlying pallets 10. When assembled, the pallet 10 may measure about 40 inches by 48 inches by 5 inches in height in accordance with an International Organization for Standardization (ISO) standard, although the invention is not so limited. Such common ISO standard pallets 10 also pack neatly into common ISO containers, which in turn fit neatly on container ships, trains, and trucks.

In one embodiment, the pallet 10 further includes cross members 34, 36 interconnecting the stringers 18. The cross members 34, 36 maintain the stringers 18 in a stable, spaced arrangement after the pallet 10 is loaded, during shipment, and when the pallet 10 is lifted and moved using a forklift. The arrangement of the stringers 18 shown in FIG. 1 includes a major dimension or length, L₁, of each stringer 18 aligned in approximately the same direction. Additionally, a major dimension or length, L₂ (FIG. 3), of each of the cross members 34, 36 is substantially perpendicular or orthogonal to the length of the stringers 18.

Cross members 34, 36 are each removably coupled to a first end portion 40 or a second end portion 42 of each of the stringers 18. Although only two cross members 34, 36 are shown, the pallet 10 may further include one or more additional cross members to further stabilize the stringers 18. For example, a third cross member (not shown) may be removably coupled to a central region 44 of each stringer 18 between the cutouts 20. The cross members 34, 36 hold the stringers 18 in a substantially fixed spatial relationship relative to each other, which lends mechanical stability to the pallet 10. For simplicity of description, cross members 34, 36 are presumed to have identical constructions so that the following description of cross member 34 applies equally to cross member 36.

With reference to FIG. 3, cross member 34 includes a plurality of U-shaped loops or brackets 50 interconnected by one or more braces 52. The number of brackets 50 may advantageously correspond to the number of stringers 18 interconnected by cross member 34. Each bracket 50 includes a first side section 54, a second side section 56 substantially parallel to the first side section 54, and a top section 58 extending between the first and second side sections 54, 56. Thus, the first and second side sections 54, 56 are separated by a gap to define a concavity 60 configured to receive one of the stringers 18. In one embodiment, the length of the first and second side sections 54, 56 is selected such that the bottom surface 28 of each stringer 18 contacts the ground surface or floor when the stringers 18 are received in the concavities 60.

The braces 52 extending between consecutive ones of the brackets 50 may be separate components attached to the brackets 50 or integrally formed with the brackets 50. For example, cross member 34 may be constructed from a continuous length of metal rod stock (e.g., ⅜″ diameter) that is deformed into a shape defining the brackets 50 and braces 52. When the pallet 10 is assembled, the braces 52 are spaced from the lower surface 16 of the deck 12 to provide room for insertion of the forklift tines in the space between the stringers 18.

As shown in FIGS. 1 and 4, a recess 68 is formed in each stringer 18 for receiving at least a portion of one of the brackets 50. Thus, the number of recesses 68 on a stringer 18 may correspond to the number of cross-members 34, 36 mechanically coupled with the stringer 18. The recess 68 extends across the top surface 26 of the corresponding stringer 18 and has a width, W₁, equal to or greater than the diameter or width of the bracket 50 to be received. The recess 68 may also have a depth equal to or greater than the diameter of the top section 58 of the corresponding bracket 50. Thus, in such an embodiment, the top section 58 is sized so that the bracket 50 does not project beyond a first plane including the top surface 26 of the stringer 18 when received in the recess 68. This arrangement helps prevent cross member 34 from interfering with the coupling between the lower surface 16 of the deck 12 and the top surface 26 of the stringer 18.

In some embodiments, the recess 68 may also be formed at least partially across a first side surface 70 of each stringer 18 for accommodating the first side section 54 or second side section 56 of the corresponding bracket 50. For example, when the stringer 18 is positioned along a first side edge 72 of the deck 12 with the first side surface 70 facing outwardly, the portion of the recess 68 extending across the first side surface 70 accommodates the first side section 54 of the corresponding bracket 50. Conversely, when the stringer 18 is positioned along a second side edge 74 of the deck 12 opposite the first side edge 72 with the first side surface 70 facing outwardly, the portion of the recess 68 extending across the first side surface 70 accommodates the second side section 56 of the corresponding bracket 50. The recess 68 may extend completely across the first side surface 70. The first side section 54 or second side section 56 of the corresponding bracket 50 may have a length approximately equal to the height of the stringer 18 so that the braces 52 are located near the bottom surface 28 of the stringers 18 when the pallet 10 is assembled.

As shown in FIG. 2, the depth of the recess 68 in the first side surface 40 may be equal to or greater than the diameter of the first side section 54 or second side section 56 so that the bracket 50 does not project beyond a plane including the first side surface 70 when received in the recess 68. Such an arrangement allows the first side surface 70 to be positioned directly against adjacent pallets 10 or other nearby objects when the corresponding stringer 18 is positioned along the first side edge 72 or second side edge 74 of the deck 12. Because a second side surface 76 of the corresponding stringer 18 faces inwardly in either of these situations, the corresponding bracket 50 is not likely to interfere with the positioning of the pallet 10 or to catch on nearby objects when it extends beyond a plane including the second side surface 76. Thus, the first side section 54 or second side section 56 of the corresponding bracket 50 may simply bear against the second side surface 76 of the stringer 18. Forming the recess 68 in only one of the first and second side surfaces 70, 76 helps limit the thinning of the stringer 18. However, if desired, the recess 68 may be formed in both the first side surface 70 and second side surface 76.

In one specific embodiment in which the cross-members 34, 36 are formed from ⅜″ diameter metal rod stock deformed into shape, the width, W1, of each of the recesses 68 is about 7/16″. The depth of the recess 68 across the top surface 26 of the corresponding stringer 18 is about ½″, and the depth of the recess 68 across the first side surface 70 is about 7/16″.

The deck 12 is depicted as a sheet of corrugated paper, although other materials and configurations are possible. For example, the deck 12 may be constructed from wooden slats secured to the stringers 18 in a juxtaposed manner. Alternatively, the deck 12 may be constructed from hardboard, solid fiber paperboard, or a sheet of plywood. The construction material of deck 12 may advantageously facilitate ready removal of deck 12 from the stringers 18 for disassembly of the pallet 10, as will be described in greater detail below. The deck 12 may be adhesively bonded by, for example, amounts of a hot melt adhesive 80 (FIG. 5) applied to the top surface 26 of each stringer 18 at spaced apart attachment points. Other techniques for coupling the deck 12 to the stringers 18 are possible, and examples of these alternative embodiments will be described below.

When the deck 12 is coupled to the stringers 18, the top section 58 of each bracket 50 is captured between the deck 12 and a base 71 (FIG. 4) of the corresponding recess 68 when the pallet 10 is assembled. As a result, vertical movement of the bracket 50 out of the recess 68 is resisted. Similarly, lateral movement of the bracket 50 along the corresponding stringer 18 is resisted by contact between the first side section 54 or second side section 56 and peripheral sidewalls 73, 75 (FIG. 4) of the corresponding recess 68. Thus, cross members 34, 36 cooperate with the deck 12 and stringers 18 to stabilize pallet 10 and impart rigidity to the construction.

In use, the deck 12 and stringers 18 are cut to size from appropriate construction materials. For example, the stringers 18 may be formed from lengths of kiln-dried wood, such as 2×4's of a suitable length, that are relatively stable against warpage. The cross members 34, 36 are likewise fabricated from their selected construction material. The stringers 18 are positioned relative to each other to define a frame for supporting the deck 12. This positioning may be achieved by assembling the stringers 18 with the cross members 34, 36. For example, the first end portion 40 on each of the stringers 18 may be first inserted into one of the concavities 60 defined by the brackets 50 on cross member 34. Such an arrangement couples the stringers 18 together in a spaced apart relationship. As described above, the top section 58 and one of the first or second side sections 54, 56 may be received in the recess 68 provided in the stringer 18. Cross member 36 may then be assembled to the second end portion 42 of each of the stringers 18 in a similar manner.

Once the deck 12 has been coupled to the stringers 18 using one or more of the techniques described above, a load (not shown) may be placed on the assembled pallet 10. In some embodiments, the load may be secured to the pallet 10 by tensioned high strength steel or plastic strapping passing over the load and down around the pallet 10, or by plastic film stretch-wrapped about the pallet 10 and load. The loaded pallet 10 is typically shipped to its destination along with many other loaded pallets, which may be identical to the pallet 10 or may be conventional pallets. At the destination, the load carried by the pallet 10 is unloaded.

If desired, the deck 12 may eventually be separated from the stringers 18 by a conventional method. For example, if made from an recyclable material such as corrugated paper, the deck 12 may be removed and then crushed, baled, and sent to a hydropulper operation to pulp the corrugated paper so that it may be put through the papermaking and corrugating process again. The cross members 34, 36 are subsequently disassembled from the stringers 18 by removing the brackets 50 from the recesses 68. The disassembled components of the pallet 10 may then be stored for re-use. The disassembled cross members 34, 36 and stringers 18 of the pallet 10 may be stored in a significantly smaller or more compact volume than conventional pallets. Typically, the volume reduction, in comparison with conventional pallets, may be as much as about 80 to 85 percent.

Alternatively, the cross members 34, 36 and stringers 18 may be shipped, with the advantages of the reduced volume, to a different location for re-use or recycling. The re-use may consist of repurchase of the cross members 34, 36 and stringers 18 by the original manufacturer, or a third party recycler, for a fraction of the original sales price. The cross members 34, 36 and stringers 18 may cleaned and sterilized as necessary for re-use.

With reference to FIG. 5, after the deck 12 is removed, small regions of the holt melt adhesive 80 and delaminated material from portions 82 on the lower surface 16 of deck 12 may remain bonded to the top surface 26 of the stringers 18. This delaminated material may represent an outer ply of the deck 12 (e.g., liner board formed from two types of pulp in which the outer ply is thinner than an underlying ply). To reduce the delamination, the hot melt adhesive 80 used to bond the deck 12 with the stringers 18 may comprise pressure sensitive adhesive and the lower surface 16 of the deck 12 may include a release coating to facilitate clean disassembly. The regions of the hot melt adhesive 80 may be removed from the stringers 18 by heating the hot melt adhesive 80 to a softening temperature and then scraping the softened adhesive residue from the top surface 26. The thermal treatment may be accomplished by moving the stringers 18 through a heat tunnel or a similar heated structure (not shown) equipped with a scraper effective to remove the thermally softened hot melt adhesive 80. Alternatively, the residue of the hot melt adhesive 80 may be removed with the assistance of a suitable solvent.

The removal of the residue of the hot melt adhesive 80 may be an additional step in re-use of the stringers 18 and cross members 34, 36. The cross members 34, 36 may be sterilized before re-use. The re-use of the stringers 18 and cross members 34, 36 represents a significant advantage of the pallets 10 of the invention.

FIGS. 6-8 illustrate alternative techniques for mechanically coupling a deck 12′ to the stringers 18. In the embodiment shown in FIG. 6, amounts of hot melt adhesive 84 are applied to the first side surface 70 of one of the stringers 18 of the pallet 10. The outermost stringer 18 on one side of the pallet 10 is spaced apart from the first side edge 72 of the deck 12′. As a result, when the deck 12′ is positioned on the top surface 26 of the outermost stringer 18, an overlap portion 86 is defined between the first side edge 72 and the outermost stringer 18. The overlap portion 86 may be folded downwardly so that the lower surface 16 of the deck 12′ confronts the first side surface 70 with portions 88 contacting the holt melt adhesive 84. The outermost stringer 18 on an opposite side of the pallet 10 may be spaced apart from the second side edge 74 (FIG. 1) of the deck 12′ and bonded to the lower surface 16 in a similar manner. Additionally, the scraping process discussed above with reference to FIG. 5 may be used to remove any residue of the holt melt adhesive 84 that remains on the fist side surface 70 of the outermost stringers 18 after the deck 12′ is removed.

With reference to FIG. 7, a deck 12″ may alternatively be coupled to the stringers 18 using rivets or studs, of which stud 90 is representative. The stud 90 may be constructed from any suitable material, including, for example, a cured hot melt adhesive. The stud 90 extends through an aperture or opening 92 cut in the deck 12″ and into a recess 94 defined in the stringer 18. The opening 92 and recess 94 are registered spatially to define a contiguous volume. Thus, molten hot melt adhesive may be dispensed into the contiguous volume and allowed to cure. Similar sets of studs 90, openings 92, and recesses 94 may be distributed along the length of the stringer 18. As a specific example, each of the stringers 18 may include six spaced apart recesses 94 and the deck 12 may include six openings 92 registered spatially with the six recesses 94. Stud 90 may be particularly advantageous for removing the deck 12″ from the stringers 18 of the assembled pallet 10 in that a knife may be routed through the interface between the deck 12″ and stringers 18 for cutting the studs 90. After the studs 90 are cut, the deck 12″ is readily removable.

It will be appreciated that other mechanical fasteners (not shown), such as staples, may be used to secure the deck 12 to the stringers 18. In this instance, when the pallet 10 is disassembled, the deck 12 should retain the mechanical fasteners. The degree of attachment between the deck 12 and stringers 18 at the attachment points should be adequate to resist deflection so that the pallet 10 can be safely lifted by a generally vertical lifting force applied to the lower surface 16 of the deck 12.

With reference to FIG. 8, a deck 12′″ may be removably coupled to the stringers 18 by placing a paperboard patch or strip 96 between the deck 12′″ and each of the stringers 18. Adhesive 98 is applied to both a top surface 100 and a bottom surface 102 of each of the paperboard strips 96 so that when the pallet 10 is assembled, the paperboard strips 96 securely hold the deck 12′″ and each of the stringers 18 together. The bond strength of the adhesive 98 is sufficient so that the pallet 10 may be used to support a load or otherwise handled. However, if desired, the deck 12′″ may still be removed from the stringers 18 using a conventional method. In one embodiment, the paperboard strips 96 are provided with a plybond (i.e., internal bond strength of individual plies) that permits the separation of the plies or fiber comprising the paperboard strips 96 when pulling the deck 12′″ off the stringers 18. As a result, fiber (not shown) from the separated paperboard strips 96 remains attached to both the lower surface 16 of the deck 12′″ and the upper surface 26 of each of the stringers 18 after the deck 12′″ is removed. The adhesive 98 and fibers of the paperboard strips 96 may then be removed using heating and scraping techniques similar to those discussed above so that the stringers 18 and/or deck 12′″ may be reused.

FIGS. 9-12 illustrate a pallet 110 according to another embodiment of the invention, with like reference numbers being used to refer to like structure from the embodiments discussed above. The pallet 110 includes the deck 12, stringers 18, and cross members 34, 36, and may be assembled and disassembled in a manner similar to the pallet 10. Accordingly, only the differences between the pallet 110 and the pallet 10 will be described below.

For example, in this embodiment, the recess 68 in each of the stringers 18 and the cross members 34, 36 have a slightly different configuration than those in the pallet 10. FIG. 10 illustrates cross member 34 in further detail, although cross member 36 may be presumed to have an identical construction such that the following description applies equally to both of the cross members 34, 36. The U-shaped loops or brackets 50 still include the substantially parallel first and second side sections 54, 56 and a top section 58. Although the first and second side sections 54, 56 are separated by a gap to define the concavity 60 for accommodating one of the stringers 18 in an edgewise manner, the distance between the first and second side sections 54, 56 of each bracket 50 is slightly larger than the width of the stringer 18. Thus, a small gap (e.g., 1/16″) is present between each bracket 50 and the corresponding stringer 18 when the pallet 110 is assembled to provide clearance between the first and second side surfaces 70, 76 of the stringer 18 and the respective first and second side sections 54, 56.

The brackets 50 may be formed from a bar of material, such as a metal bar stock (e.g., ⅛″ by ½″), that can be deformed to assume the concave shape. The braces 52 may be formed from lengths of rod material that can be joined or secured with the brackets 50 at attachment points near the entrance to the corresponding concavities 60. For example, the braces 52 may be formed from metal rod stock (e.g., ⅜″ or ½″ in diameter) welded to the deformed metal bar stock constituting the brackets 50. In alternative embodiments, the brackets 50 and braces 52 may be formed from a continuous length of metal bar stock deformed to define the brackets 50, which eliminates the need to join the braces 52 with the brackets 50. In other embodiments, the brackets 50 and/or braces 52 may be constructed from wood, plastic, combinations of these materials, or combinations of these materials and metal. In one specific embodiment, the cross members 34, 36 are formed from steel, the stringers 18 are constructed from wood, and the deck 12 is corrugated paper.

With reference to FIGS. 11 and 12, each of the recesses 68 in this embodiment defines a keyhole notch having a slot 120 communicating with the top surface 26 of the corresponding stringer 18 and a bore 122 extending through the width of the corresponding stringer 18. The diameter, D₁, of the bore 122 is greater than the width, W₁, of the slot 120. Furthermore, the diameter, D₁, of the bore 122 is greater than a width, W₂, of the corresponding bracket 50, and the width, W₁, of the slot 120 is less than the width, W₂, of the corresponding bracket 50. To insert, for example, the bracket 50 in FIG. 11 into the recess 68, the cross member 34 is oriented such that a relatively thin side edge 124 of the bracket 50 is aligned with the slot 120. The side edge 124 is moved through the slot 120 to the bore 122 and then rotated approximately 90° to engage the bracket 50 with the recess 68. Because the width, W₂, of the bracket 50 exceeds the width, W₁, of the slot 120, the bracket 50 cannot be removed through the slot 120 without rotating the cross member 34 such that the thin side edge 124 of bracket 50 is re-aligned with the slot 120.

The recesses 68 may be positioned anywhere between an end 126 of the corresponding stringer 18 and the nearest cutout 20. In some embodiments, the recesses 68 may be keyhole notches oriented such that the slots 120 communicate with (i.e., open to) the ends 126 of the stringers 18 instead of the top surface 26.

The pallets of the various embodiments of the invention have a number of advantages over existing pallet constructions. Among these advantages is that the pallets of the various embodiments of the invention may be quickly and conveniently disassembled. For example, the pallet 10 or the pallet 110 may be assembled in less than one minute using a hot melt adhesive gun (not shown). When a large number of pallets of the various embodiments of the invention are stored or transported in an unloaded state, the stringers 18 may be stacked on top (and beside) one another and substantially without any empty space therebetween. In one embodiment, the stringers 18 and cross members 34, 36 of 80 disassembled pallets may be stacked on an assembled pallet without exceeding 5 feet in height.

Similarly, storage and transport of the cross members 34, 36 requires a minimum packing space. When stored or transported without a load, the volume of the disassembled pallets of the various embodiments of the invention may be is reduced by 85 percent or more in comparison with the volume occupied by conventional pallets. The construction of the pallets of the various embodiments of the invention also has a reduced tare weight in the absence of a load. Consequently, the pallets of the various embodiments of the invention may be disassembled and stored or transported to another location for reuse with more efficient use of space and mass requirements. This in turn reduces the expense associated with non-used pallets.

Among the other advantages, the deck 12 may be formed from corrugated paper, which is recyclable. In the modular design, the assembled pallet of the various embodiments of the invention may be easily disassembled to separate the stringers 18 and cross members 34, 36 into separate components. The stringers 18 and cross members 34, 36 are reusable so that a waste stream is not generated. The stringers 18 and cross members 34, 36 can be easily sterilized and coupled with a fresh sterile deck. If desired, the stringers 18 and cross members 34, 36 can be stored outside in an uncontrolled environment. The pallets of the various embodiments of the invention can be placed or stored on wet surfaces because the stringers 18 can be constructed from a non-moisture sensitive material.

Furthermore, the pallets of the various embodiments of the invention may be assembled without nails or staples. Specifically, the stringers 18 and cross members 34, 36 may be assembled without tools and the deck may be adhesively bonded to the stringers. The construction of the pallet in the various embodiments of the invention is cost effective and is also strong and stable even when supporting relatively heavy loads. Also, in comparison with, for example, conventional all-wooden pallets, the pallets of the various embodiments of the invention are fully exportable.

The pallets of the embodiments of the invention may also be printed with a bar code or equipped with a radio frequency identification (RFID) tag for use in load tracking. The RFID tag may be attached to or incorporated into, for example, the deck 12. The RFID tag may contain electrical circuits, memory, and antennas, but no internal power source, to enable it to passively receive and respond to radiofrequency queries from a transceiver.

While the invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept. 

1. A pallet, comprising: a deck; a plurality of beam members mechanically coupled with the deck; and a first cross member bridging the beam members, the first cross member mechanically coupled with each of the beam members such that the beam members have a substantially fixed spatial relationship relative to each other.
 2. The pallet of claim 1 wherein the beam members are arranged with a substantially parallel relationship and the first cross member is oriented substantially transverse to the beam members.
 3. The pallet of claim 1 wherein the first cross member is secured to the beam members without mechanical fasteners.
 4. The pallet of claim 1 wherein the deck is adhesively bonded to the top surface of each of the beam members.
 5. The pallet of claim 1 wherein the deck comprises corrugated paper.
 6. The pallet of claim 1 wherein each of the beam members includes a top surface and a side surface, and at least one of the top surface or the side surface of each of the beam members is mechanically coupled with the deck.
 7. The pallet of claim 1 wherein each of the beam members includes a top surface and a first recess defined in the top surface, the first cross member includes a plurality of brackets, and each of the brackets is at least partially received in the first recess of a respective one of the beam members.
 8. The pallet of claim 7 wherein each of the beam members includes a side surface, the first recess of each of the beam members extends across at least a portion of the respective side surface, and each of the brackets has a top section received in the respective first recess proximate the top surface and a side section received in the respective first recess proximate the side surface.
 9. The pallet of claim 8 wherein the top section and the side section of at least one of the brackets is sized to be received in the respective first recess so that the at least one bracket does not project beyond a first plane including the top surface of the respective beam member or beyond a second plane including the side surface of the respective beam member.
 10. The pallet of claim 7 wherein each of the brackets is defined by a first side section, a second side section substantially parallel to the first side section, and a top section extending between the first and second side sections to define a concavity configured to receive one of the beam members.
 11. The pallet of claim 7 wherein the first cross member comprises a continuous length of metal rod stock deformed to define the brackets.
 12. The pallet of claim 7 wherein the first recess in at least one of the beam members defines a slot communicating with the top surface and a bore extending through the at least one beam member, the bore having a first diameter and the slot have a first width less than the first diameter, and the at least one bracket received in the first recess of the at least one beam member having a second width greater than the first width and less than the first diameter.
 13. The pallet of claim 7 further comprising: a second cross member bridging the beam members, the second cross member mechanically coupled with each of the beam members, and the second cross member cooperating with the first cross member to provide the beam members with the substantially fixed spatial relationship relative to each other.
 14. The pallet of claim 13 wherein each of the beam members includes a second recess defined in the top surface, the second cross member includes a plurality of brackets, and each of the brackets of the second cross member is at least partially received in the second recess of a respective one of the beam members.
 15. The pallet of claim 1 further comprising: a second cross member bridging the beam members, the second cross member mechanically coupled with each of the beam members, and the second cross member cooperating with the first cross member to provide the beam members with the substantially fixed spatial relationship relative to each other.
 16. A method of handling a pallet including a deck, a plurality of beam members, and at least one cross member, the method comprising: positioning the beam members relative to each other to define a frame for supporting the deck; mechanically coupling the at least one cross member with each of the beam members so that beam members have a substantially fixed spatial relationship relative to each other; and mechanically coupling the deck to a surface of each of the beam members.
 17. The method of claim 16 wherein the at least one cross member includes a plurality of brackets each defined by a concavity, and wherein mechanically coupling the at least one cross member with each of the beam members further comprises: receiving the beam members in the concavity of each of the brackets of the at least one cross member.
 18. The method of claim 16 wherein mechanically coupling the deck with each of the beam members further comprises: applying adhesive to the surface of each of the beam members; contacting the deck with the adhesive; and curing the adhesive to provide the mechanical coupling between the deck and the beam members.
 19. The method of claim 16 further comprising: delivering a load on the pallet to a first location; removing the deck from the beam members; disassembling the at least one cross member from the beam members; transporting the beam members and the at least one cross member in a disassembled condition from the first location to a second location; and reassembling the pallet at the second location.
 20. The method of claim 19 wherein the deck is coupled to a top surface of each of the beam members by adhesive, the method further comprising: scraping any remaining adhesive from the top surface of each of the beam members after the deck is removed.
 21. A method for reusing a pallet including beam members, a deck supported by the beam members, and at least one cross member mechanically coupling the beam members together, the method comprising: removing the deck from the beam members; disassembling the at least one cross member from the beam members; and transporting the disassembled beam members and the at least one cross member from a first location to a second location.
 22. The method of claim 21 further comprising: reassembling the at least one cross member and the beam members at the second location; and coupling a deck to the beam members.
 23. The method of claim 21 further comprising: selling the beam members or the at least one cross member at a first price; and repurchasing the beam members or the at least one cross member at a second price less than the first price.
 24. The method of claim 21 further comprising: preparing the at least one cross member and the beam members for re-use at the second location; transporting the at least one cross member and beam members to a third location; reassembling the at least one cross member and the beam members at the third location; and coupling another deck to the beam members. 